FI130249B

FI130249B - Method of producing a food product

Info

Publication number: FI130249B
Application number: FI20225390A
Authority: FI
Inventors: Santtu Vekkeli
Original assignee: Ne Innovations Oy
Priority date: 2022-05-05
Filing date: 2022-05-05
Publication date: 2023-05-09
Also published as: WO2023214121A1; FI20225390A1

Abstract

It is disclosed a method of producing a food product comprising a poultry meat material and a plant-based food material, comprising the steps of: providing a gutted and plucked poultry meat material comprising bones; providing a plant-based food material; grinding the gutted and plucked poultry meat material with a meat grinder having a hole size of at most 5 mm to provide a ground poultry mass; adding the plant-based food material to the ground poultry mass to provide a poultry/plant mixture; subjecting the poultry/plant mixture to a wet extrusion to provide an extruded mass; mincing the extruded mass with a colloid mill to provide a minced extruded mass as a food product.

Description

METHOD OF PRODUCING A FOOD PRODUCT

FIELD OF THE INVENTION

The present invention relates to a method of producing a food product.

More particularly, the invention relates to a method of producing a food product by extrusion and colloid milling from poultry including undervalued parts of poul- try.

BACKGROUND OF THE INVENTION

Extrusion is widely used in the manufacture of various food products.

Broadly, extrusion is a continuous process which uses an extruder having one or two screws. The extruder provides transport, compression, mixing, cooking, shear- ing, heating, cooling and shaping of raw material to final products.

US 5853790 discloses a method for commercial preparation of poultry meat for human consumption by using extrusion. The method effectively maxim- izes the use of poultry meat from an entire poultry carcass, and enhances the value of all of the meat from a bird carcass. The meat portions of whole birds are de- boned in the method.

RU 2223673 discloses a method for producing combined extrusion products from meat and vegetable raw materials. Poultry meat used in the method is mechanically deboned. Veins, tendons and skin may be used in the production.

It has now been found that a food product for human consumption with satisfactory organoleptic properties, such appealing taste and good mouthfeel, comprising a poultry meat material and a plant-based food material, may be pro- duced from undervalued parts of poultry meat material containing bones, and op- tionally additionally, e.g, hard tissues, tendons, skin and/or cartilages. Poultry = 25 meat from an entire poultry carcass may be effectively used and converted to a val-

N uable food product with consumer acceptable organoleptic properties. The satis- 3 factory organoleptic properties of the food product are provided by grinding an x extruded food mass containing poultry meat material and a plant-based food ma-

T terial using a colloid mill. a

S 30 BRIEF DESCRIPTION OF THE INVENTION 0 In an aspect, the present invention provides a method for producing a

S food product from a poultry meat material and a plant-based food material. The method effectively utilizes all meat from bird carcass including bones, and option- ally hard tissues, tendons, skin and/or cartilages.

The invention thus provides a sustainable method in which whole gut- ted and plucked bird may be effectively used in the production of a ready-to-con- sume food product for human consumption providing environmental benefits. Ad- ditionally, the food product can be used as an ingredient or extender and combined with other food materials to produce a wide range of food compositions.

The food product produced by the method of the invention is also suit- able as an animal feed.

The invention also provides a method in which undervalued parts of a bird or of low hygienic quality may be used providing economic benefits in that the product can be offered at a lower cost.

The invention further provides a method of producing a food product with an increased nutritional value.

Further, the invention provides a method of producing a food product which enables reduction of global meat production providing environmental ben- — efits.

The invention also provides a method of producing a food product with high microbiological guality and substantially eliminated Salmonella bacteria.

In another aspect, the invention provide a food composition comprising a food product produced by the method of the invention.

In further aspect, the invention provides an apparatus comprising means for implementing the method of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 generally illustrates a process flow diagram of an embodiment of the method of the invention. - 25 Figure 2 illustrates an embodiment of an apparatus of the invention.

N

N DETAILED DESCRIPTION OF THE INVENTION

3 It is disclosed a method of producing a food product comprising a poul- 3 try meat material and a plant-based food material, comprising the steps of:

Ek - providing a gutted and plucked poultry meat material comprising - 30 bones, 2 - providing a plant-based food material, a - grinding the gutted and plucked poultry meat material with a meat grinder having a hole size of at most 5 mm to provide a ground poultry mass, - adding the plant-based food material to the ground poultry mass to provide a poultry/plant mixture,

- subjecting the poultry/plant mixture to a wet extrusion to provide an extruded mass, - mincing the extruded mass with a colloid mill to provide a minced ex- truded mass as a food product.

In an aspect, the invention is as defined in claim 1.

Figure 1 illustrates an embodiment of the method of the invention. The dotted line illustrates optional method steps. The method may include further op- tional method steps not shown in the figure.

Poultry meat material suitable for use in the method of the invention includes, but is not limited to, chickens, turkeys, ducks, and geese. In an embodi- ment of the invention, the poultry is chicken.

The gutted and plucked poultry meat material comprises bones. The content of the bones in the gutted and plucked poultry meat material may vary in the range of about 10 wt-% to about 60 wt-%. Use of increased amount of bones in — the gutted and plucked poultry meat material beneficially results in an increased amount of calcium in the final food product.

In an embodiment, the gutted and plucked poultry meat material fur- ther contains hard tissues, tendons, skin and/or cartilages, and can be provided by legs, necks, skin and/or heads of poultry.

The gutted and plucked poultry meat material is ground to crush bones and other hard tissues and to provide a ground poultry mass which is in a suitable form to be fed to a wet extrusion. The grinding is carried out with a meat grinder having a hole size of at most 5 mm. In an embodiment, the meat grinder has a hole size in the range of about 2 mm up to 5 mm.

In an embodiment, the ground poultry mass is subjected to a colloid mill n to further crush bone particles to smaller pieces. Generally, “colloid mill” is a ma-

S chine which has a high-speed rotor and a stator providing superfine grinding re- 5 sults along with simultaneous emulsifying, homogenizing, and dispersing. The ro- > tor pushes the material into small gaps between the rotor and stator causing in- © 30 tense mechanical shear. In the present invention, colloid milling provides a homog- z enous, ultra-fine bone particles of bone-containing poultry mass and beneficially

S enhances softening of bone particles in the subseguent wet extrusion. In an em- i bodiment, colloid milling of the ground poultry mass provides bone particles hav-

N ing an average particle size of at most 500 um.

N 35 After grinding with a meat grinder, and optional further grinding with a colloid mill, the obtained ground poultry mass is mixed with a plant-based food material. Any food-grade plant-based food material is suitable to be added to the ground poultry mass. The plant-based food material includes, but is not limited to, a food material which is rich in protein, carbohydrate and/or fibre. In an embodi- ment, the plant-based food material comprises soy protein, pea protein, cereal pro- teins, broad bean protein, maize protein, potato starch, maize starch, or any mix- ture thereof. In an embodiment, the plant-based food material is provided as finely ground powder. In an embodiment, the plant-based food material is thoroughly mixed with the ground poultry mass to provide a uniform poultry/plant mass mix- ture.

The plant-based food material is added to the ground poultry mass in an amount so as to provide a food product containing about 5 wt-% to about 50 wt- % of the plant-based food material. In an embodiment, the food product contains about 10 wt-% to about 30 wt-% of the plant-based food material.

In an embodiment, the food product contains about 50 wt-% to about 95 wt-% of the gutted and plucked poultry meat material. In another embodiment, the food product contains about 70 wt-% to about 90 wt-% of the gutted and plucked poultry meat material.

In an embodiment, the poultry/plant mass mixture is cooled to a tem- perature of about -25°C to about 6°C. Cooling of the poultry/plant mass mixture improves microbiological quality of the mass mixture before feeding it to the ex- trusion process.

The poultry/plant mass mixture is subjected to a wet extrusion to pro- vide an extruded mass. In context of the present invention, the term “wet extru- sion” means that the poultry/plant mass mixture to be extruded has a moisture content of at least 30%. In an embodiment, the moisture content of poultry/plant n mass mixture is in the range of 30% to about 70%. If the moisture content is lower

N than 30%, it may be difficult to carry out the extrusion process, since the mass mix- n ture in the extruder is dry. On the other hand, if the moisture content is higher than 7 70%, liquid is undesirably separated from the dry matter of the mass mixture. © 30 The wet extrusion may be carried out with a single-screw or twin-screw z extruder. Shearing and tearing combined with moisture in the extrusion step o causes softening of the hard tissues of poultry and provides a unigue structure to a the final food product.

N In an embodiment, the wet extrusion is performed at a temperature of

N 35 about 100°C to about 400°C. Depending on the extruder used in the method, the extruder has to contain at least one heating segment where the temperature is at least 100°C. In addition, there may be further heating segments where the extru- sion may be performed below 100°C, e.g., at 70°C. In an embodiment of the inven- tion, an extruder is used which contains several heating segments each operated at a different temperature. In an embodiment, the temperature of the heating seg- 5 ments increases when the mass moves forward in the extruder.

The duration of the wet extrusion is dependent on the apparatus con- struction and settings.

In an embodiment, the wet extrusion is performed using about 100 rpm to about 1000 rpm speed. In another embodiment, the wet extrusion is performed using about 170 rpm to about 600 rpm speed. In an embodiment, about 170 rpm is employed in the wet extrusion.

In an embodiment, the wet extrusion of the ground poultry mass pro- vides an extruded mass having a temperature of at least 100°C.

In an embodiment, the extruded mass is cooled to a temperature of about +60°C to about -30°C. In an embodiment, cooling of the extruded mass is per- formed in an extruder before the extruded mass is discharged from the extruder.

Cooling in the extruder is conveniently carried out in the cooling die. When the ex- truded mass is cooled in the extruder, the temperature of the mass discharged from the extruder may range from about 1°C to about 80°C. In an embodiment, the tem- perature of the extruded mass is in the range from about 30°C to about 60°C.

The extruded mass is then minced with a colloid mill to improve the sensory properties of the obtained food product. The colloid mill at this stage may be the same as or different from the colloid mill used for grinding the ground poul- try mass. In an embodiment, water and/or oil is added to the extruded mass before colloid milling to enhance the performance of colloid milling. Grinding of the ex- n truded mass with a colloid mill provides a food product containing bones with an

S average particle size of about 1 um to about 500 um. The colloid milled food prod-

LÖ uct exhibits a smooth mouth feel without observable bone particles present. = The colloid milling of the extruded mass provides a food-grade product © 30 which is ready to be consumed as such.

E Extrusion process decreases microbial load of poultry carcass enabling o use of poultry of low hygienic guality. Microbial load is reduced by approximately a 1000-10° fold during the process.

N The extruded food product produced by the method of the invention

N 35 may imitate the texture, flavour, and mouthfeel of meat.

The method of the invention provides a food product which exhibits an increased nutritional value. By using calcium-containing parts of poultry, ie, bones, and optionally hard tissues, tendons, and/or cartilages, the calcium content of the food product produced by the method is increased compared with typical poultry meat products. In an embodiment, the food product has a calcium content of about 0.2% w/w to about 0.7% w/w. In another embodiment, the calcium con- tent of the food product is about 0.2% w/w to about 0.5% w/w, such as about 0.52% w/w. In a further embodiment, the calcium content of the food product is about 0.5% w/w to about 0.7% w/, such as about 0.52% w/w.

In an embodiment, the extruded and colloid milled food product is heat- treated at a temperature ranging from about 110°C to about 400°C to further im- prove sensory properties and mouthfeel of the product. The heat treatment may be carried out, e.g., by cooking in oil, e.g., at 150-300°C, grilling, pan frying, drying by heat, e.g., at 200-400°C, freeze drying below -70°C, microwaving or infrared radi- ating.

The sensory properties of the food product may be further improved by adding ingredients typically used in food manufacture to the food product pro- duced by the method of the invention, e.g., flavouring agents, aromas, salt, stabi- lizers, emulsifiers, carbohydrates, fibres, oils and fats, etc.

The food product may be combined with other food materials to pro- vide a wide variety of food compositions having different appearance, taste and structure. Thus, in an aspect, the invention provides use of a food product produced by the method of the invention as an ingredient or extender in the production of food compositions. The food product may be combined, for example, with a plant- based food raw material or poultry meat material without bones, hard tissues, ten- dons, skin and/or cartilages. The food product produced by the method of the in- n vention may be included in the food composition in an amount up to about 50%

N w/w without imparting any negative effect on the sensory properties of the food n composition. 7 In another aspect, the invention provides a food composition compris- © 30 ing a food product produced by the method of the invention.

E In a further aspect, the invention provides an apparatus for implement-

S ing the method of the invention, comprising means for implementing the method 2 of the invention. An embodiment of the apparatus of the invention is illustrated in

N figure 2. The dotted line illustrates optional units. The apparatus may include fur-

N 35 ther optional units not shown in the figure.

The following examples are presented for further illustration of the invention without limiting the invention thereto.

The calcium content of the food product was measured according to standard SFS-EN ISO 11885, 2009.

The level of aerobic microorganisms was measured according to stand- ard NMKL 86:2013.

The amount of Salmonella was measured according to ISO/DIS 20976- 2.

Example 1 70 kg of poultry carcass (with bones and skin) was minced with a meat grinder with a hole size of 2 mm. The ground poultry mass was then colloid milled to a fine mass with bone particles with approximately diameter of 100 um. Milled mass was properly mixed with 30 kg of a soy concentrate powder (protein content of 66 wt.%). The resultant mixture was kept at approximately 4°C. The mixture was then loaded to a silo connected to a conveyor screw that was connected to a hopper with approximately 30 liters of volume. The mixture was led from the hopper with an auger and a screw to an extruder in a controlled manner at approximately 55kg/h.

The mixture of ground poultry mass and a soy concentrate powder was led to an extruder which had a cooling die integrated therewith. The moisture con- tent of the mixture was about 55% w/w. The mixture was extruded at 170 rpm.

Heating zones of the extruder were adjusted to a temperature of 60°C, 70°C, 80°C, 100°C, 120°C, 150°C and 170°C. First zone of the cooling die was set to 60°C and last zone to 40°C. The extrusion process took about one minute.

The extruded mass exited the cooling die at a temperature of less than 100°C. Only small amount of steam was released in the process. Solid mass and n some amounts of separated oil exited the end of the cooling die.

S The level of aerobic microorganisms of the solid mass obtained from the n wet extrusion and that of the mixture of ground poultry mass and a soy concentrate ? powder to be fed to the wet extrusion, i.e., "raw material”) were measured at

S 30 30°C/72 h. The solid mass showed < 100 pmy/g, while the raw material showed

E more than 30 000 000 pmy/g. The measured level of aerobic microorganisms indi- o cates that a food grade product for human consumption was obtained. a The food product, i.e., solid mass, had a calcium content of 0.52% w/w.

N The solid mass exhibited 7-log reduction of Salmonella bacteria indicat-

N 35 ing that Salmonella was completely eliminated.

The solid mass was ground with a meat grinder having a hole size of 2 mm. Sunflower oil and water were both added to the ground mass each in a ratio of 2:10 (w/w) and were left to be absorbed by the mass at 4°C for 60 minutes.

Batches of the mass were then milled with a colloid mill. The colloid milling pro- vides a mass which is a ready-to-consume food product.

The mass may also be used as an ingredient of a food composition in an amount up to 50 wt-% of the total weight of the food composition.

Example 2

The extruded mass was produced as described in Example 1. The ex- truded mass was torn to particles having a particle size of about 1-5 mm. Fresh ground chicken meat was added to the particles in a ratio of 65:35 (w/w). Beef fat was added to the obtained mixture in a ratio of 1:10 (w/w) followed by grinding by a meat grinder with a 5 mm sieve to provide a dough. 2.0 wt-% of salt and spices including black pepper powder, hot pepper powder, cumin powder, garlic powder, onion powder and cayenne pepper were added to the dough. The dough was kneaded for about 20 minutes until a smooth mass was obtained. The mass was wrapped in an oil-coated aluminum foil, baked in an oven at 125°C until the internal temperature of the kebab-like mass was 80°C.

Product was cooled to +4°C and vacuum packaged.

The resultant kebab-like food product exhibited an appealing taste and mouthfeel.

It will be obvious to a person skilled in the art that, as the technology advances, the inventive concept can be implemented in various ways. The inven- tion and its embodiments are not limited to the examples described above but may n vary within the scope of the claims.

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Claims

1. Amethod of producing a food product comprising a poultry meat ma- terial and a plant-based food material, comprising the steps of: - providing a gutted and plucked poultry meat material comprising bones, - providing a plant-based food material, - grinding the gutted and plucked poultry meat material with a meat grinder having a hole size of at most 5 mm to provide a ground poultry mass, - adding the plant-based food material to the ground poultry mass to provide a mixture of the ground poultry mass and the plant-based food material, - subjecting the mixture having a moisture content of about 30 wt-% to about 70 wt-% to a wet extrusion to provide an extruded mass, - mincing the extruded mass with a colloid mill to provide a minced ex- truded mass as a food product.

2. The method of claim 1, wherein the gutted and plucked poultry meat material contains bones in an amount of about 10 wt-% to about 60 wt-% based on the weight of the gutted and plucked poultry meat material.

3. The method of claim 1 or 2, wherein the gutted and plucked poultry meat material further contains at least one of hard tissues, tendons, skin and carti- lages.

4. The method of any one of the preceding claims, wherein the ground poultry mass is further ground with a colloid mill.

5. The method of any one of the preceding claims, wherein the plant- based food material comprises soy protein, pea protein, cereal proteins, broad bean protein, maize protein, or any mixture thereof.

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6. The method of any one of the preceding claims, wherein the plant- N based food material is added in an amount so as to provide a food product contain- S ing about 5 wt-% to about 50 wt-%, specifically of about 10 wt-% to about 30 wt- S %, of the plant-based food material. E 30

7. The method of any one of the preceding claims, wherein the food o product contains about 50 wt-% to about 95 wt-%, specifically of about 70 wt-% to a about 90 wt-% of the gutted and plucked poultry meat material.

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8. The method of any one of the preceding claims, wherein the wet ex- N trusion is carried out at a temperature of about 100°C to about 400°C.

9. The method of any one of the preceding claims, wherein the wet extrusion is performed at about 170 rpm.

10. The method of any one of the preceding claims, wherein at least one of water and oil is added to the extruded mass prior to mincing with a colloid mill.

11. The method of any one of the preceding claims, wherein minced ex- truded mass has an average bone particle size of about 1 um to about 500 um.

12. The method of any one of the preceding claims, wherein the food product has a calcium content of about 0.2% w/w to about 0.7% w/w, specifically about 0.2% w/w to about 0.5% w/w, more specifically about 0.5% w/w to about

0.7% w/w.

13. A food composition comprising a food product produced by the method of any one of claims 1 to 12 in an amount up to about 50% w/w of the food composition.

14. An apparatus comprising means for implementing the method of any one of claim 1-12, wherein the means comprises - a meat grinder for grinding a gutted, plucked poultry meat material to provide a ground poultry mass, - an extruder connected with the meat grinder and configured to receive the ground poultry mass to provide an extruded mass, - a colloid mill connected with the extruder and configured to receive the extruded mass to provide a food product. S N O N LÖ ? co O I a a O O O LO N N O N